Electrical and electronic systems always include hardware components. If you want to develop a hardware module, e.g. for a controller or a sensor, but lack the know-how or simply the development capacity, then NTC Systems is the right place for you. Our engineers are always looking forward to developing new hardware. Tackling new projects is always exciting.
- Are you looking for a partner for the independent development of a hardware component?
- Do you need support with the design and implementation of your hardware?
- Do you need support in analyzing your hardware with regard to quality standards or safety norms?
- Should your hardware be optimized or supplemented with regard to quality standards or safety norms?
The engineers at NTC Systems advise and support you through all phases of hardware development. You can even entrust us with the complete hardware development you need. We develop the hardware components you need according to your requirements and specifications. Our experts also think proactively during the specification phase. Our ideas and proposed solutions have often optimized a concept or a procedure, because we are experienced across many industrial sectors, especially in safety-critical systems.
Development of safety-relevant hardware – specify, develop, test
Our services cover the independent implementation of hardware development as well as consulting and support in hardware development across all phases. We also assemble the hardware into a prototype so that real physical tests can be carried out.
- Prototype | for testing and validation or as a demonstrator
- Small series | from supply to maintenance
Requirements – analyze, prioritize, document
- This includes the analysis and prioritization of hardware requirements.
- We help with structuring and documenting the requirements (SRS creation).
Hardware architecture – design, build, define behavior
- We design the structure and behavior of the hardware.
- Or we can support you in designing the structure and behavior of the hardware
- Physical components
- Logical components
- Their interfaces
- Observance of the performance criteria
- We advise and support the implementation of redundancies for fail-safe mechanisms and fault diagnosis mechanisms.
- We carry out safety analyses based on your hardware architecture, e.g. FMEDA
Detailed Design – specify, implement, review
- Here we create a detailed design at module level.
- We advise and support you in specifying the hardware modules and defining the interfaces in detail.
- By carrying out reviews, we help to provide tested modules for further steps.
Hardware-Testing – plan, check, verify
- We specify test cases and carry out tests at all levels of the hardware.
- We advise you on the definition of test plans, test coverage, test processes and support you in the specification of test cases.
- When carrying out hardware tests (verification), we support
- at module level | Hardware Design Verification
- at integration level | Hardware Integration and Testing
- for the complete hardware | Hardware Qualification Testing
- Functional tests under realistic operating conditions
- Environmental impact and thermal tests
- Mechanical tests for mechanical stability
- Electrical tests regarding parameters, residual current and short-circuit resistance
- EMC tests for electromagnetic compatibility
NTC Systems – comprehensive E/E development
E/E System Development
E/E Development | Processes
E/E Development | Software
Reference projects for E/E Hardware Development
Development of a Safety-Oriented Remote I/O PLC
Approach | From Concept to Secure Implementation
The development of the Remote I/O PLC demonstrates the strong commitment to functional safety and technical excellence by NTC Systems. Throughout the project, close collaboration with the customer was maintained, meticulously managing each phase of the development lifecycle to ensure adherence to the highest safety standards.
Picture: Remote I/O PLC (Programmable Logic Controller)
Key phases of successful development
- Concept Development
A well-defined concept is essential for every project. For the Remote I/O PLC, a thorough safety concept was initiated, involving the definition of safety requirements through an extensive risk analysis, determining the necessary Safety Integrity Level (SIL) or Performance Level (PL), and selecting appropriate architectures to achieve functional safety. Various solution approaches were assessed, leading to the selection of the optimal concept that met both technical requirements and the stringent specifications outlined in IEC 61508 and ISO 13849.
- Schematics Creation and Review
Following the approval of the concept, detailed creation of circuit diagrams was undertaken. From the beginning, safety architecture (e.g., 1oo2D redundancy for safety-related inputs and outputs) and EMC requirements were considered. Each design underwent rigorous internal and external reviews to identify potential errors early and ensure alignment with the established safety objectives.
- Comprehensive Test Specification and Execution
A critical phase of the project involved developing an extensive test specification. This encompassed not only the functionality of the Remote I/O PLC but also focused specifically on safety tests, including the validation of fault reactions, verification of diagnostic functions, and measurement of safety response times. Tests were conducted in a controlled environment, simulating various operational and fault conditions, and utilizing state-of-the-art testing equipment to ensure the system’s reliability and safety.
- Detailed Test Report Generation
Each test result was meticulously documented. The generated test reports were comprehensive and transparent, offering detailed descriptions of the test environment, sequences, observed outcomes, and verification of safety requirements. These reports served as critical evidence for validating functional safety and were essential for the product’s subsequent certification.
- Expert Support in Functional Safety Aspects
Throughout the project, extensive support was provided for all aspects of functional safety. This included consulting on safety analysis, risk assessment, derivation of safety requirements, and the creation of necessary safety documentation. Active involvement in defining safety lifecycle processes ensured the seamless implementation of requirements from IEC 61508, ISO 13849, and IEC 61131, particularly regarding software and hardware design principles for PLCs.
Picture: Tools for the development of a Remote I/O-PLC
- Automotive
- Railroad Technology
- Mechanical Engineering
- Medical Technology
- Automation and process Industry